Shingle and method of making the same



A ia 25, 1944.

C.v B. BURNETT SHINGLE AND METHOD OF MAKING THE SAME Filed March 19, 1941 INVENTOR raw 8. 602N577.

AfToRNEY will otherwise overcome Patented Apr. 1944 Clinton B. Burnett, Waukegan, 111.,

Johns-Manville Corporation, a'corporatlon of New. York Application March. 19, 1941, Serial No. 384,063 8 Claims. (Cl. ill-30) The instant invention relates to covering units, and particularly to individual or strip shingles of the type cut from a continuous sheet or-web,

impregnated with a waterproofing material such as asphalt, coated with asphalt, or the like, and surfaced. with a granular mineral material. I

Heretofore, it hasbeen known in the art to prepare such shingles from an asphalt-impregnated felt. According to the more conventional methods, the impregnated felt is supplied with a uniform coating of asphalt in which is partially embedded a surfacing of a comminuted mineral,

such as crushed'slate, or the like, and individual shingles or strip shingles are cut therefrom. In

the manufacture of shingles of the so-called 4 thick butt" type, a second asphalt coating and comminuted mineral layer are applied to overlie that portion of the web to constitute the butt or exposure portions of the shingles. In the conventional strip shingle, in which the individual tained by the improved shingle of the instant inshingle-simulating tabs are defined by slots extending inwardly from the butt edge to a point slightly above the upper limits of the exposure area, the second coating and surfacing layer usually terminate on a line substantially coincident with the upper ends of said slots. Such thick butt shingles have been preferred over those with asingle coating and surfacing layer due to the increased weight and durabilit of the butt portions and also the thicker butt line presenting a more pleasing appearance. However, although these shingles have enjoyed wide commercial usage, they have not sufficiently met the requirements of the art by reasonvof the inherent disadvantages arising from the termination of the.

overlay coating at a line substantially defining the upper limits of the exposure area. For example, the two-level characteristic of such shingles has no counterpart in wooden shingles. Furthermore, the termination of the reinforcing overlay along tends-to bend when its butt portion is subjected to lifting forces such ashigh winds, reduces its resistance to such lifting through what is, in effect, the hinge condition between the upper portion and the butt portion of the shingle.

The principal object of the instant invention is the provision of a shingle which will-have a thick butt appearance, but which will be reduced in thickness more uniformly from the butt edge to the upper edge of the disadvantages of the present commercial shingle.

Another object of the invention is the provision or a shingle of the type referred to which will the lineuponwhich the shinglethe headlap area, and which assignor to New York, N. Y.,

have the desired weight distribution to place the major weight of the shingle in the butt portion to inhibit lifting of the butt.

A further object of the invention is the provision of" a'method of making an improved shingle of the type referred to involving relatively in-' expensive operations.

Briefly stated, the foregoing objects are atvention, comprising a first coating or any suitable or conventional bituminous material, such as asphalt, carrying a continuous surfacing of granular material on the butt portion and a minor'amount or discontinuous layer on the granular material on the remaining portion. A second coating of asphalt overlies the entire upper face of the shingle. A granular material'predominanty of a given is partially embedded in the second coating over the butt portion of the shingle, and a granular material predominantly of a smaller size is partially embedded in the second coating on the headlap area, the two, however, blending to avoid an'abrupt juncture line. Also, the shingle in the preferred form has a substantial taper from a maximum thickness at the butt edge to the upper edge of the headlap area, the taper resulting from the arrangement of coating and surfacing layers. 4

The invention will be more fully understood and further objects and advantages thereof will become apparent when reference is made to the more detailed description thereof which is to follow and to the accompanying drawing, in

which:

Fig. 1 is a perspective view of a strip shingle in accordance with the instant invention;

Fig. 2 is a sectional view taken on the line 2- of Fig. 1; I

Fig. 3 is a diagrammatic view illustrating the method employed in the instant invention;

Fig. 4 is a diagrammatic sectional view taken on the line l-lof Fig: 3 in the direction indicated by the arrows;

Fig. 5 is a diagrammatic sectional view-taken on the line 5-5 of Fig. 3 in the direction indi s-1b cated by the arrows;

Fig. 615 a diagrammatic sectional view taken on the line 66 of Fig. 3 in the direction indicated by the arrows;

Fig. 'l is a diagrammatic sectional view taken ,on the line '|'I of-Fig. 3 in'the direction indicated by the arrows; and

Fig. 8 is a plan view of a roofing sheet or web depicting the arrangement of "the coating and surfacing materials in the several stages of the method of the instant invention. I

Referring now to the drawing, and more particularly to Figs. 1 and 2, there is shown a covering unit It, depicted for the purposes of illustration as a strip shingle, having a plurality of shingle-simulating tabs l2 defined by slots I4 and a headlap area it to be overlapped by a shingle of a next higher course when the shingle is applied. It will be understood, however, that the invention may equally well be embodied in an individual shingle, a shingle with hexagonal tabs, or any other conventional shingle shape.

Shingle comprises a base l8, which, in accordance' with conventional practice, may be an asbestos felt, rag felt, or the like, impregnated with any of the known waterproofing materials used for this purpose, such, for example, as a relatively low melt point asphalt. The under surface of the base carries a relatively thin coating of a waterproofing materiaLsuitably asphalt, in which is embedded talc particles, or the like, 22, which serve to Prevent adhesion of the shingle to an underlying shingle in the shingle bundle.

In accordance with the instant invention, theupper surface of base l8 carries a coating layer or the like, is indicated at 40.

between the two areas. The predominant granules on the headlap area may, for example, be #20 granules and may or may not differ in color with respect to the granules on the butt, depending upon the effect desired.

A shingle in accordance with the invention as described above does not exhibit any definite shoulder between the butt and headlap areas and at least gives the appearance of substantial umformity of taper from the butt edge to the upper edge. Furthermore, the greatest weight of the shingle per unit of area isin the butt, whereby the shingle tabs are not susceptible to ready lifting under the action of high winds.

Referring now particularly to Figs. 3 to 8, inclusive, the manufacture of the shingles of the invention will be described. A web of felt, or the like, as conventionally employed in asphalt roofing, and saturated with a suitable waterproofing compound, such as low melt point asphalt, Web 40 is suitably of a width ta permit a plurality of lanes of shin- 24 which is relatively thick over that portion of the shingle to be exposed during use and relatively thin over the headlap area of the shingle, as shown particularly in Fig. 2. Coating 24 is suitably a relatively high melt point asphalt, or other bituminous material conventionally used for coating purposes. The coating layer may be of substantially uniform thickness over the part of the shingle to be exposed (hereinafter referred to as the buttkareah and likewise, of a substantially uniform but lesser thickness over the remaining area of the shingle (hereinafter referred to as the "headlap area). However, it is preferred that the coating on the headlap area taper from the upper edge of the butt area to the upper edge of .the headlap area. Embedded in coating 24 over the butt area is a substantially continuous layer of a granular material 26, such as scrap crushed slate, mastic sand, mineral wool shot, and the like, or a mixture thereof. The granular material 26 extends to some extent onto the coating covering-the headlap area ,to form a discontinuous layer sufficient to prevent sticking of the shingle to various parts of the apparatus during the manufacturing operations.

Overlying the coated and slated shingle sur-.

face is a second coating layer- .28, preferably of a high melt point asphalt similar to that employed for the first coating layer. The upper surface of layer 28 suitably tapers with respect to base sheet l8 at least over the headlap area so that the shingle has its thinnest portion at the upper edge of the headlap area. Preferably, s ch taper extends substantially uniformly throughout from a maximum thickness at the butt edge to the upper edge of the headlap area. Partially embedded in the second coating layer 28 is a surfacing layer 30. Over the butt portion of the shingle the surfacing layer is formed of mineral granules, such as crushed slate, or the like, predominantly of the size conventionally used on the exposure areas of shingles of this general type. Thus, for example, #11 granules may be used. Surfacing layer 30 on the headlap is predominantly composed of granules of a smaller size, but has intermixed with such smaller granules a minor proportion of the granules used on the butt area to submerge the line of jointure gles to be cut therefrom. For purposes of example, the web is shown to be of a width to accommodate two lanes of strip shingles, with the lengths of the strips extending longitudinally of the web. The web, moving in the direction indi cated by the arrow, passes first beneath a spout 42', or other suitable means to deliver coating asphalt thereon and then beneath a coating or spreading r011 44. PvOll 44 is suitably shaped to distribute the coating in a relatively thick layer over the center portion of the web, which is to constitute the butts of the shingles, and a relatively thin layerover the margins of the web, which are to constitute the shingle headlap areas. As illustrated particularly in Fig. 4, preferably roll 44 is shaped to taper the coating on the marginal edges of the web from a maximum depth equal to that on the butt portions to a minimum depth at the web edges. A coating roll 46 is located beneath the web and is supplied with coating material, for example, through rotation in coating-filled chamber 48. I The roll transfers a thin layer of coating to the under surface of the web.

' After receiving the coating the web passes beneath a. hopper '50 having a discharge slot extending across the central portion of the web a suflicient distance to discharge granular material contained in the hopper onto the coating of the butt lanes to provide a substantially uniform layer thereon, with an excess overflowing to some extent onto the coating of the headlap lanes to provide a discontinuous fragmentary layer of granular material on the latter portions of the coated web. The Web then passes around an embedding roll 52, whereby the applied granular material is partially embedded in the coating. The coating on the under side of the web is covered with a back surfacing, such as talc, I

discharged from a hopper 54. The talc is partially embedded in the under coating as the web passes around roll 56, and the coating layers are then permitted to set and hardenas the web travels around cooling rolls 58 or througha cooling' looper, or. the like.

Web 40 then passes to a second coating applicator, comprising, for example, a coatin spout 60 discharging a suitable coating material on the upper surface of the web, and. roll 62 shaped (see Fig. 6) to distribute the coating so that the greater weight of the same is on the butt lanes of the web and the lesser proportion on the headlap lanes. As illustrated, preferably such distriably suitably divided, or otherwise arranged as indicated diagrammatically in Fig. 7, to discharge granules of a given size onto the butt lanes and granules of predominantly a smaller size onto the headlap lanes. Mixed in with the granules of smaller size is a small proportion, say, or less of the headlap granules. The granules are partially embedded in the second coating as the web passes around an embedding roll 55, and

excess granules are collected in trough 68. The mixture of granules for the headlap areas is suitobtained by including a desired proportion of the granules collected in trough 68 with the upply of smaller size granules.

Web 40 is then carried to cutting roll 60, suitably constructed in accordance with conventional practice to cut out slots H and to longitudinally slit the sheet into two individual shingle lanes, as indicated at 12 in Fig. 8. The plurality of lanesare divided into individual shinglesby suitable cutters, preferably carried by roll 10, all in accordance with conventional practice, and the shingles are discharged onto a collecting device, as indicated diagrammatically at H.

As will be understood by those skilled in the art, the apparatus described above, in explaining the method, is only representative of that which may be employed and any of the conventional means may be substituted to carry out the individual steps. Also, having thus described the invention in rather full detail, it will be understood that these details. need not be strictly adhered to, but that various changes and modifications will suggest themselves, all falling within the scope of the invention as defined by the subjoined claims.

What is claimed is:

1. A covering mated with a waterproofing material, a surface of said unit carrying a bituminous coating layer, said layer being of greater but substantially uniform thickness over a portion of the unit substantially that to be exposed, a substantially continuous layer of granular material partially embedded in the coating on said portion, said granular material extending to and forming-a discontinuous layer on the remaining area of said surface, a second bituminous coating layer covering'said surface of the unit and a granular material predominantly of a given size partially embedded in said secondmating on said portion, and granular material predominantly of a smaller size partiallyembedded in the second coating over the remaining area of said surface.

2. A covering unit comprising a base impregnated with a waterproofing material, a surface of said unit carrying a bituminous coating layer thereon. said layer tially uniform thickness over a portion of the unit substantially that to be exposed and of lesser thickness over the remaining area, asubstanttally continuous layer of granular materialpartially embedded on said portion and extending to and forming a discontinuous layer on said remaining area, a second bituminous coating layer covering said surface of 'the unit and including an upper surface tapering with respect to said base from the butt edge to the upper edge of the unit, and granular material partially embedded in said second coating.

' coating of lesser thickness unit comprising a base. impregcoating tapering with respect being of greater but substan- 3. A covering unit, comprising a base impregnated with a waterproofing material, a surface -of said unit carrying a bituminous coating layer portion and extended to form a discontinuous layer on the remaining coated area, a second bituminous coating layer covering said surface of the unit and tapering with respect to the base from the butt edge to the upper edge of the unit, granular material predominantly or a given size partially embedded in said second coating on said portion, and granular material predominantly of a smaller size partially embedded in the remaining area of said second coating, a minor proportion of said granular material of a given size being intermixed with the granular material on said remaining area.

- 4. A strip shingle comprising an asphalt-saturated felt base having a plurality of slots extending inwardly from the butt edge thereof to define shingle-simulating tabs,-an asphalt coating layer on the upper face of .said base, said layer being of greater but substantially uniform thickness over that portion of the base defined by the butt edge of said tabs and a line adjacent the upper ends of said slots. a layer of asphalt covering the remaining area of said face, a substantially continuous layer' of granular material partially embedded in the coating on said portion and extending to and forming a discontinuous layer on the remaining area of said face, a second layer of asphalt coating covering said face of the unit. and granular surfacing material partially embedded in said second coating.

5. A strip shingle comprising an asphalt-saturated felt base having a plurality of slots extend-- ing inwardly from the butt edge thereof to define shingle-s ulating tabs, an asphalt coating layer on the upper face of said base, said layer being of greater but substantially uniform thickness over that portion of the base defined by the butt edge of said tabs and a line adjacent the upper ends of said slots, a layer of asphalt coating of lesser thickness covering the remaining area of said face, a substantially continuous layer of granular material partially embedded in the coating on said portion and extended to and forming a discontinuous layer on said remaining area, a second layer of asphalt coating covering said face of the unit, the upper surface of said second to the shingle base thickness at the butt edge of from a maximum said shingle to a minimum thickness at the upper edge thereof, and granular surfacing .mate- I rial partially embedded in said second coating.

web of a width to have severed therefrom one or more lanes of covering units, a layer of a plastic, bituminous coating material of a greater but material in said coating, applying a second layer of bituminous coating to overlie the entire surface of said web, partially embedding in said second coating a second, layer of granular material, and severing covering units from said web.

7. A method of making covering units comprising applying to the surface of a saturated web of a width to have severed therefrom one or more lanes of covering units, a layer of plastic, bituminous coating material of greater but substantially uniform thickness on that portion of the web to constitute the exposed portions ofthecovering units and of tapering thickness on the remaining areas of the web, showering granular material on the coating of greater thickness to form a substantially continuous layer thereon and a discontinuous layer on the remainder of the coating, partially embedding said granular material in said coating, applying a second layer of bituminous coating to overlie the surface of said web, showering a granular material predominantly of a given size on the coating overlying said portion and predominantly of a smaller size on the coating overlying said remaining areas,

rated felt web of a width to have severed therefrom one or more lanes of strip shingles extending longitudinally of the web, a layer of a plastic asphalt coating of a greater but substantially uniform thickness on that portion of the web to constitute the butt portions of the strip shingles and of a tapering thickness on that portion of the web to constitute the headlap areas of such strip shingles, showering a granular material on the coating of greater thickness to form a substantially continuous layer while permitting said granular material to overflow to form a discontinuous layer on the remaining area of the coating, partially embedding said granular material in'said coating, applying a second layer of asphalt coating to cover the entire surface of said web in such a manner that the upper surface of said second coating tapers with respect to the face of said web from a line defining the butt edges of said strip shingles to a line defining the upper edge of the headlap areas thereof, showering granular material predominantly of a given size on said second coating covering said exposure areas and predominantly of a smaller size -on the remaining area of said coating, partially embedding said granular material in said coating, slotting and slitting said web, and severing strip shingles therefrom.

CLINTON B. BURNETT.

CERTIFICATE OF- CORRECTION.

Patenfi No. 2,5h7,25o. April 25; 191 1;.

GLINTOfI B. fiRNETT.

It is hereby oertified that error appears in the printed specification ofthe above numbered patent requiring correotion as'followsz Page 1, first and second column,

551 line 1 .5, for "-condition' read -vconnection-, line 114., for "on", firet occurzfenoe, Patent should 1 s read with this correct form to the record of the base in the Patent Office.

Signed and sealed this 20th ds of June, A. 11191 1 ion therein that the same may con- Leslie Frazer (Seal) 'Aot ing Commissioner of Patents.

read ofand that the said Letters 

